Sonotrode State Monitoring Using a Reference Test Specimen
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Solution Overview
Problem
Existing vibration machining systems, particularly those using ultrasonic vibrations, face challenges in monitoring their state effectively, leading to unsatisfactory welding results due to wear and tear, as current methods only detect issues after they have caused deviations in workpiece quality.
Innovation Solution
A method and system for monitoring the state of vibration machining systems by comparing measurement parameters with reference parameters during operation, using a test body to determine if the system is within a tolerance range, and issuing warnings or adjusting parameters to maintain quality, with the ability to adapt to changes in system components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If workpiece quality monitoring is performed during welding, then weld quality can be determined and good parts identified, but system state changes cannot be detected early and only become known when unsatisfactory welding results occur
Solution Approach 1:
The patent applies preliminary action by introducing a test body into the welding system before actual workpiece welding to perform preliminary measurements of system parameters. This allows the system state to be monitored and evaluated before actual production welding occurs, enabling early detection of system changes such as sonotrode wear. The measurement of system parameters using a test body precedes the welding process, allowing preventive maintenance actions to be taken before workpiece quality deteriorates.
2Measurement precision
If individual workpiece properties are measured during welding, then weld quality can be assessed, but deviations between workpieces prevent direct conclusions about system state
Solution Approach 1:
The patent uses a test body as an intermediary object between the welding system and actual workpieces. This test body serves as a standardized mediator that receives welding energy under controlled conditions, allowing system parameters to be measured without the variability introduced by different workpiece properties. The test body translates system state into measurable parameters while eliminating the influence of workpiece deviations, enabling reliable conclusions about system state.
3Reliability
If continuous monitoring of system parameters is implemented, then early detection of system changes is possible, but additional measurement and comparison infrastructure is required
Solution Approach 1:
The patent applies copying by using a test body that replicates the essential characteristics of workpiece-material combinations without requiring actual workpieces. The test body creates a simplified copy of the welding interaction, allowing system parameters to be measured in a controlled manner. This copying approach enables monitoring infrastructure to focus on measuring system parameters rather than dealing with the complexity of varying workpiece properties.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables early and reliable detection of system state changes, allowing for proactive maintenance and ensuring consistent welding quality by identifying deviations before they affect workpieces.
Implementation Method 1
The generator is used to generate electrical vibrations, in particular ultrasonic vibrations
Implementation Method 2
The converter generates mechanical vibrations from the high-frequency electrical vibrations and transmits them to the sonotrode
Implementation Method 3
When the working surface of the sonotrode is in contact with the specimen, vibrations are introduced from the sonotrode into the specimen
Data Source
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AI summary
In a method for monitoring the condition of a vibration processing system (10), a working surface (15) of a sonotrode (13) is brought into contact with a test specimen (30), the sonotrode (13) exerting a force (F) on the test specimen (30). Ultrasonic vibrations (S) are introduced into the test specimen (30) by the sonotrode (13), while at least one measurement parameter (M) of the vibration processing system (10) is simultaneously determined. The measurement parameter (M) is then compared with a reference parameter (R), and based on this comparison, it is determined whether the measurement parameter (M) lies within a tolerance range (T) around the reference parameter.